Spray texture material compositions, systems, and methods with anti-corrosion characteristics

Abstract

A system for dispensing texture material in a desired spray pattern that substantially matches an existing texture pattern on a target surface has a container assembly, an actuator assembly, and a concentrate comprising a solvent/carrier comprising water, wall texture material comprising at least one filler and a resin/binder, a first anti-corrosion material, where the first anti-corrosion material is a phosphate ester, and a second anti-corrosion material, where the second anti-corrosion material is sodium nitrite. At least one of the first and second anti-corrosion materials forms a film on the inner surface of the container assembly while the concentrate is stored within the container assembly. The film inhibits corrosion of the corrodible material forming at least part of the inner surface of the container assembly. The first and second anti-corrosion materials together comprise 0.125-7.00% by weight of the concentrate.

What is claimed is: 
     
       1. A system for dispensing texture material in a desired spray pattern that substantially matches an existing texture pattern on a target surface, comprising:
 a container assembly defining an inner surface formed at least in part of a corrodible material; 
 an actuator assembly defining an outlet opening having an adjustable cross-sectional area; and 
 a concentrate comprising
 a solvent/carrier comprising water, 
 wall texture material comprising at least one filler and a resin/binder, 
 a first anti-corrosion material, where the first anti-corrosion material is a phosphate ester, and 
 a second anti-corrosion material, where the second anti-corrosion material is sodium nitrite; wherein 
 
 the concentrate is disposed within the container assembly such that the water is exposed to the inner surface of the container assembly; 
 at least one of the first and second anti-corrosion materials forms a film on the inner surface of the container assembly while the concentrate is stored within the container assembly, where the film inhibits corrosion of the corrodible material forming at least part of the inner surface of the container assembly; 
 the concentrate passes through the outlet opening in a spray pattern that forms the desired texture pattern on the target surface; and 
 the first and second anti-corrosion materials together comprise 0.125-7.00% by weight of the concentrate. 
 
     
     
       2. A system as recited in  claim 1 , in which:
 the first anti-corrosion material comprises 0.1-5.0% by weight of the concentrate; and 
 the second anti-corrosion material comprises 0.025-2.00% by weight based on total weight of the concentrate. 
 
     
     
       3. A system as recited in  claim 1 , in which:
 the solvent/carrier comprises 25-65% of by weight based on total weight of the concentrate; and 
 the at least one filler comprises 20-70% by weight based on total weight of the concentrate. 
 
     
     
       4. A system as recited in  claim 1 , in which:
 the solvent/carrier comprises 38-58% of by weight based on total weight of the concentrate; and 
 the wall texture material comprises 41-61% by weight based on total weight of the concentrate. 
 
     
     
       5. A system as recited in  claim 1 , in which:
 the solvent/carrier comprises 25-45% of by weight based on total weight of the concentrate; and 
 the filler comprises 48-68% by weight of the concentrate. 
 
     
     
       6. A system as recited in  claim 1 , in which:
 the solvent/carrier comprises 47-67% of by weight based on total weight of the concentrate; and 
 the wall texture material comprises 31-51% by weight based on total weight of the concentrate. 
 
     
     
       7. A texture material concentrate to be dispensed in a desired spray pattern from a container assembly defining an inner surface formed at least in part of a corrodible material using an actuator assembly defining an outlet opening having an adjustable cross-sectional area, where the desired spray pattern that substantially matches an existing texture pattern on a target surface, the texture material concentrate comprising:
 a solvent/carrier comprising water, 
 wall texture material comprising at least one filler and a resin/binder, 
 a first anti-corrosion material, where the first anti-corrosion material is a phosphate ester, and 
 a second anti-corrosion material, where the second anti-corrosion material is sodium nitrite; wherein 
 the concentrate is disposed within the container assembly such that the water is exposed to the inner surface of the container assembly; 
 at least one of the first and second anti-corrosion materials forms a film on the inner surface of the container assembly while the concentrate is stored within the container assembly, where the film inhibits corrosion of the corrodible material forming at least part of the inner surface of the container assembly; 
 the concentrate passes through the outlet opening in a spray pattern that forms the desired texture pattern on the target surface; and 
 the first and second anti-corrosion materials together comprise 0.125-7.00% by weight of the concentrate. 
 
     
     
       8. A texture material concentrate as recited in  claim 7 , in which:
 the first anti-corrosion material comprises 0.1-5.0% by weight of the concentrate; and 
 the second anti-corrosion material comprises 0.025-2.00% by weight based on total weight of the concentrate. 
 
     
     
       9. A texture material concentrate as recited in  claim 7 , in which:
 the solvent/carrier comprises 25-65% of by weight based on total weight of the concentrate; and 
 the at least one filler comprises 20-70% by weight based on total weight of the concentrate. 
 
     
     
       10. A texture material concentrate as recited in  claim 7 , in which:
 the solvent/carrier comprises 38-58% of by weight based on total weight of the concentrate; and 
 the wall texture material comprises 41-61% by weight based on total weight of the concentrate. 
 
     
     
       11. A texture material concentrate as recited in  claim 7 , in which:
 the solvent/carrier comprises 25-45% of by weight based on total weight of the concentrate; and 
 the filler comprises 48-68% by weight of the concentrate. 
 
     
     
       12. A texture material concentrate as recited in  claim 7 , in which:
 the solvent/carrier comprises 47-67% of by weight based on total weight of the concentrate; and 
 the wall texture material comprises 31-51% by weight based on total weight of the concentrate. 
 
     
     
       13. A texture material concentrate as recited in  claim 7 , in which the solvent/carrier comprises 25-45% of by weight based on total weight of the concentrate. 
     
     
       14. A method for dispensing texture material in a desired spray pattern that substantially matches an existing texture pattern on a target surface, comprising:
 providing a container assembly defining an inner surface formed at least in part of a corrodible material; 
 supporting an actuator assembly defining an outlet opening having an adjustable cross-sectional area relative to the container assembly; and 
 providing a concentrate within the container assembly, the concentrate comprising
 a solvent/carrier comprising water, 
 wall texture material comprising at least one filler and a resin/binder, 
 a first anti-corrosion material, where the first anti-corrosion material is a phosphate ester, and 
 a second anti-corrosion material, where the second anti-corrosion material is sodium nitrite, where 
 the first and second anti-corrosion materials together comprise 0.125-7.00% by weight of the concentrate; 
 
 arranging the concentrate within the container assembly such that
 the water is exposed to the inner surface of the container assembly, and 
 at least one of the first and second anti-corrosion materials forms a film on the inner surface of the container assembly while the concentrate is stored within the container assembly, where the film inhibits corrosion of the corrodible material forming at least part of the inner surface of the container assembly; and 
 
 operating the actuator assembly such that the concentrate passes through the outlet opening in a spray pattern that forms the desired texture pattern on the target surface. 
 
     
     
       15. A method as recited in  claim 14 , in which:
 the first anti-corrosion material comprises 0.1-5.0% by weight of the concentrate; and 
 the second anti-corrosion material comprises 0.025-2.00% by weight based on total weight of the concentrate. 
 
     
     
       16. A method as recited in  claim 14 , in which:
 the solvent/carrier comprises 25-65% of by weight based on total weight of the concentrate; and 
 the at least one filler comprises 20-70% by weight based on total weight of the concentrate. 
 
     
     
       17. A method as recited in  claim 14 , in which:
 the solvent/carrier comprises 38-58% of by weight based on total weight of the concentrate; and 
 the wall texture material comprises 41-61% by weight based on total weight of the concentrate. 
 
     
     
       18. A method as recited in  claim 14 , in which:
 the solvent/carrier comprises 25-45% of by weight based on total weight of the concentrate; and 
 the filler comprises 48-68% by weight of the concentrate. 
 
     
     
       19. A method as recited in  claim 14 , in which:
 the solvent/carrier comprises 47-67% of by weight based on total weight of the concentrate; and 
 the wall texture material comprises 31-51% by weight based on total weight of the concentrate.